Method and device for producing a metal strip in a strip casting machine with rolls

ABSTRACT

The invention concerns a method for producing a metal strip, whereby molten metal is continuously poured between two casting rolls ( 1, 2 ) of a strip casting machine with rolls. Above the molten bath ( 4 ) and respectively proximate to the molten bath ( 5 )/casting rolls ( 1, 2 ) transition surface a rotating magnetic field is produced which generates, in the molten metal, local turbulent flows, so that a surface current is formed in said molten metal, which surface current is directed by the casting rolls ( 1, 2 ) towards the central plane (E) of the molten bath ( 4 ), that is towards the plane for output of the metal strip ( 8 ), thereby enabling to largely prevent supernatant impurities at the surface of the molten bath and oxides located on the surface of the rolls from being deposited, and the molten metal particles from being prematurely solidified.

[0001] The invention relates to a method of producing a metal strip by a continuous casting of a metal melt between two casting rolls of a roll strip casting machine and to an apparatus for carrying out the method.

[0002] In the casting of a metal strip of the type described at the outset, a layer of impurities and oxides floats to the surface of the molten metal bath between casting rolls. In addition, during the feed of the molten metal and the movement of the casting rolls surface waves and surface streams in the melt result in an upward flotation of the liquid metal and a movement of the impurities on to the casting rolls. As a consequence, there is a danger that parts of the melt will be more intensively cooled on the cooled casting rolls and will prematurely solidify. In addition, the impurities and oxides flush onto the casting roll surfaces by the turbulent molten bath surface and are entrained by the casting rolls. This can create nonuniformities in the strip surface and reduce the strip quality.

[0003] The present invention has as its object to provide a method of the type set forth at the outset and an apparatus for carrying out the method which largely eliminates the danger that impurities and oxides will settle out on the casting roll surfaces and of the premature solidification of portions of the metal melt.

[0004] These objects are achieved according to the invention by a method with the features of claim 1 as well as by an apparatus with the features of claims 11 and 20.

[0005] Preferred additional features of the invention are found in the dependent claims. In accordance therewith, above the melt bath proximal to the respective melt bath surface/casting roll interface, respective magnetic rotation fields and thus local eddy currents are generated in the melt such that a flat surface current [flow] arises in the melt which is directed away from the casting rolls toward a median plane of the melt bath, that is toward the outlet plane of the melt bath and, with a limited energy expenditure, hinders the undesired premature solidification of the parts of the metal melt along the casting roll edges. The impurities and oxides are transported away from the casting roll.

[0006] The invention is described below in greater detail in connection with the drawing. The drawing shows purely diagrammatically:

[0007]FIG. 1 two casting rolls of a roll strip casting machine with a molten metal bath between them and with the respective devices for generating a surface flow in the melt respectively located above the melt bath surface and juxtaposed with each casting roll and extending along the respective casting roll; and

[0008] FIGS. 2 to 9 different embodiments of the apparatus of FIG. 1.

[0009] In FIG. 1 two casting rolls 1 and 2 are indicated which are rotatable about horizontal axes and whose rotation directions have been designated with D₁ and D₂. To produce a metal strip 8, between the two casting rolls 1 and 2 and two lateral seals 3 provided at the lateral end regions of the casting rolls 1 and 2, a molten metal is poured by a pouring device 6 [pourer] which will not be described in greater detail. The molten metal bath is designated at 4 in FIG. 1 and its upper surface with the reference numeral 5. The metal strip 8 which is produced is formed in the throughgoing gap 7 between the two cooled casting rolls 1, 2 and is displaced in the direction of the arrow B. The outlet plane of the metal strip 8 corresponds to the median plane E of the molten metal bath 4 in which the pourer 6 lies.

[0010] Above the molten metal bath surface 5, according to the invention, proximal to the casting roll surfaces, devices 10, 10′ are disposed to produce magnetic rotary fields which extend along the casting rolls 1, 2. Various embodiments of these devices are described in greater detail in conjunction with FIG. 2-9. The directions of rotation [senses] of the magnetic rotary fields have been represented in FIG. 1 at F₁, F₂ and have rotation axes A₁, A₂. As a consequence of the magnetic rotary field, in the electrically conductive metal melt, local electrical eddy currents are produced which apply forces to the conductive melt so that, in the melt, surface flows arise which are directed (see arrows S₁, S₂) away from the casting rolls 1, 2 toward the median plane E of the molten metal bath 4. The surface flows prevent, on the one hand, premature and undesired solidification of parts of the melt at the casting roll surface/melt bath surface interface and, on the other hand, the settling out of impurities and oxides on the casting roll surfaces and their entrainment by the casting rolls 1, 2. The impurities and oxides are transported away from the casting roll and can be removed along the pourer 6 which is located in the median plane E.

[0011] As is known, the casting rollers 1, 2 can be provided on their surfaces as a rule with a nickel coating. Eddy currents are also generated in this nickel coating by means of the magnetic rotary fields and give rise locally to a slight temperature increase which additionally reduces the premature hardening of the melt on the cool roll surfaces. Below, various embodiments of the devices 10, 10′ for generating the magnetic rotary fields are described based upon FIGS. 2 to 9. FIG. 2 shows a coil system 10′a which extends along the casting roll 2 and is arranged above the molten metal bath 4 proximal to the interface between the molten metal bath surface 5 and the casting roll 2 and which comprises a coil carrier 15 of circular cross section which is fixed in place and has a number of conductors 16 or coils arranged around its periphery. These are so switched that with a multiphase excitation using phase-shifted alternating current, a rotary magnetic field having a rotational sense F₂ is produced whose pattern is indicated by the line FV. The rotation axis A₂ of this rotary field coincides with the axis of the coil carrier 15. As has already been indicated, the metal melt on the molten metal bath surface 5 is displaced by the interaction of the rotary field with the field produced by electric eddy currents generated in the melt away from the casting roll 2 in the direction of arrow S₂ and is pressed flat. The surface of the melt is thereby calmed and the upward flapping of the liquid metal and the impurities onto the surfaces of the casting rolls is hindered. The impurities and oxides are displaced toward the median plane E of the molten metal bath 4 by electronic feed of the coil system 10′a. The excitation of the coil can advantageously be effected with a controlled frequency and intensity as a function of the casting parameters. Preferably the feed of the coil system 10′a and the feed of the opposite coil system juxtaposed with the other casting roll 1 can be separate from one another and for that purpose multiphasal controllable electronic feed sources which are known per se can be used. As a result, the field strength and the frequency can optimally be matched to the requirements of the process. In addition the position of the respective coil systems above the melt bath surface can be detected by appropriate sensors which can be used to optimally control the process.

[0012] The excitation of the coils can be effected with a multiphasal alternating current with sine-shaped, rectangular-shaped or another suitable pulse wave form.

[0013]FIG. 3 shows a coil system 10′b with coils electrically offset through 120° (see conductors 16 x, 16 y, 16 z; 16 u, 16 v, 16 w on the periphery of the coil carrier 15) which is excited by means of a three-phase alternating current.

[0014] According to FIG. 4 another coil carrier 15 c which is fixed in place has a coil system 10′c with a lower surface 18 c provided so as to be juxtaposed with a molten bath surface 5 and parallel to the latter, which has a plurality, preferably three, conductors 16 w, 16 x, 16 v which are parallel to and equispaced from the molten melt bath surface 5 whereby the electric current effect in the melt is additionally amplified (compare arrow S₂).

[0015] The same effect is achieved by the coil system illustrated in FIG. 5 at 10′d which has the rectangular cross section of a coil carrier 15 d, whereby again the lower surface turned toward the melt bath surface 5 has a number of conductors 16 d which are parallel to one another and to the molten metal bath 5 and are equispaced therefrom. The coil carrier 15 d has a central passage 20 traversed by a cooling medium. The cooling of the coil system is effected preferably with the otherwise available inert cooling gas so that the cooling gas is low. If higher powers of the coil system are required, then the cooling medium can be nitrogen in liquid form.

[0016] A central passage 20 traversed by the cooling medium is also possessed by the coil carrier 15 e of the coil system 10′e illustrated in FIG. 6. The cross section is here again of circular shape and is provided at its periphery with a coil carrier 15 e provided with conductors 16 e and disposed within a ceramic tube 22. The coil carrier 15 e's further provided with a number of cutouts 23, preferably six in number, distributed over the periphery and which together with the inner surface 24 of the ceramic tube 22 define a number of cooling passages traversed by the cooling medium.

[0017] The coil system 10 f of FIG. 7 encompasses externally the coil carrier 15 which is again provided in a ceramic tube and which provides a field shielding 27 comprised preferably of steel sheet or ferrite.

[0018] With all of the aforedescribed coil systems, the conductors are preferably insulated with a temperature-resistant oxide (for example a pyrothenaxone insulation). The conductors can also be directly traversed by a cooling medium. The excitation of the coils is obtainable with small section cable feeds.

[0019] It is especially advantageous to have the conductor or coil at the periphery of the coil carrier run in a spiral pattern. In that case the melt receives an additional force component that is directed away from the side seal or side seals and which is used to transport away impurities and oxides.

[0020] Another kind of device 10 h, 10 i for generating magnetic rotary fields is illustrated in FIGS. 8 and 9. Instead of locally fixed coil systems, above the molten metal bath surface 5 rotary magnet carriers 30 h or 30 i are arranged along respective casting rolls and have a number of cooled permanent magnets 31 h or 31 i affixed to them. As a result of the rotation of the permanent magnet arrangement magnetic rotary fields are produced which interact with the local eddy currents and bring about the desired flow of the melt. In addition, local eddy currents can thereby be generated in the surface nickel coating of the passing roll 1, 2, which results in a slight local temperature increase at the casting roll surfaces and counteracts premature solidification of the melt at these locations.

[0021] The magnetic carriers 30 h, 30 i also have each a respective central channel 33 traversed by a cooling medium or have cooling openings otherwise and are surrounded by a ceramic tube 32.

[0022] In the variant shown in FIG. 8, the permanent magnets 31 h are arranged peripherally on the magnet carrier 30 h. In the embodiment according to FIG. 9, the permanent magnets 31 i are arranged radially of the rotation axis A₁ of the magnet carrier 30 i. The rotation axis A₂ or A₁ of the magnet carriers 30 h or 30 i are in both variants simultaneously the rotation axes of the rotary magnetic field.

[0023] The method according to the invention and the apparatus according to the invention for carrying out the method enable a substantial increase in the quality of the metal strip to be produced and is simple from the point of view of operation technology and is cost effective.

[0024] With this method, in addition, there is a damping and flattening of the surface in the liquid region so that straight solidification lines are obtainable. The two devices 10 and 10′ are preferably so controlled that they form solidification lines of the same height. 

1. A method of producing a metal strip (8) by continuous casting of a metal melt between two casting rolls (1, 2) of a roll strip casting machine, characterized in that above the molten metal bath (4) proximal to the respective interface between the molten metal bath surface (5) and the casting roll (1 or 2) respective magnetic rotary fields are generated and thus local eddy currents are formed in the melt such that a surface flow arises in the melt which is directed away from the casting rolls (1, 2) toward the median plane (E) of the molten metal bath (4), that is toward the outlet plane of the metal strip (8).
 2. The method according to claim 1, characterized in that by means of the rotary magnetic field, local eddy currents are produced in a surface layer of the casting roll which is preferably comprised of nickel, where a slight local temperature increase arises at the casting roll surface which counteracts a premature solidification of the metal melt.
 3. The method according to claim 1 or 2, characterized in that the rotary magnetic field is produced by coil systems (10′a; 10′b; 10′c; 10′d; 10′e; 10 f) extending along the casting rolls (1, 2) above the molten metal bath (4) with each coil system having a coil carrier (15; 15 c; 15 d; 15 e) on the periphery of which conductors (16; 16 x, 16 y, 16 z, 16 v, 16 u, 16 w) or coils are so arranged and switched that the magnetic field is produced by a multiphasal alternating current which can be regulated as required with respect to frequency and intensity and can be phase shifted, the magnetic rotary field interacting with the field of eddy currents on the molten metal bath surface (5) to displace the melt away from the casting rolls (1, 2).
 4. The method according to claim 3, characterized in that the excitation of the coils with multiphasal alternating current is effected with a sinusoidal, rectangular or other suitable pulse shape.
 5. The method according to claim 3, characterized in that the conductors (16 x, 16 y, 16 z, 16 v, 16 u, 16 w) are electrically offset through 120° about the periphery of the coil carrier (15) and are excited by a three-phase alternating current.
 6. The method according to claim 3, characterized in that with a spiral pattern of the conductors (16; 16 x, 16 y, 16 z, 16 v, 16 u, 16 w) at the periphery of the coil carrier (15; 15 c; 15 d; 15 e) an additional force component is produced at the molten metal bath surface (5) and is oriented counter to force components directed toward the casting roll ends.
 7. The method according to claim 3, characterized in that a separate electronic feed is provided for the coil systems (10′a; 10′b; 10′c; 10′d; 10′e; 10 f) arranged along the two casting rolls (1, 2).
 8. The method according to claim 3, characterized in that the positions of the coil systems (10′a; 10′b; 10′c; 10′d; 10′e; 10 f) with reference to the molten metal bath surface (5) are measured and controlled.
 9. The method according to claim 1, characterized in that by means of a linear conductor arrangement parallel to one another and to the molten metal bath surfaces (5) and at the same distances therefrom, the surface flow in the melt is increased.
 10. The method according to claim 1, characterized in that the rotational magnetic field is produced by rotation of a magnet carrier (30 h; 30 i) arranged above the molten metal bath (4) along the respective casting roll (1, 2) and provided with a number of cooled permanent magnets (31 h; 31 i).
 11. An apparatus for carrying out the method according to 8 claim 1, characterized in that above the molten metal bath (4) and along each of the respective casting rolls there is a coil system (10′a; 10′b; 10′c; 10′d; 10′e; 10 f) which encompasses a fixed coil carrier (15; 15 c; 15 d; 15 e) on the periphery of which a number of multiphasal conductors (16; 16 x, 16 y, 16 z, 16 v, 16 u, 16 w) or coils are carried.
 12. The apparatus according to claim 11, characterized in that the coil carrier (15 d; 15 e) is provided with at least one channel (2) traversed by a cooling medium.
 13. The apparatus according to claim 11, characterized in that the coil carrier (15 d; 15 e) have a circular cross section.
 14. The apparatus according to claim 11, characterized in that the coil carriers (15; 15 e) are surrounded by ceramic tubes (22).
 15. The apparatus according to claim 14, characterized in that the coil carrier (15 e) at the periphery has a number of recesses (23) which, together with the inner surface (24) of the ceramic tube (22) form a number of cooling passages.
 16. The apparatus according to claim 11, characterized in that the coil carrier (15 c; 15 d) has a parallel surface (18 c; 18 d) which is provided with a number of conductors (16 w, 16 x, 16 v; 16 d) arrayed alongside one another.
 17. The apparatus according to one claim 11, characterized in that the coil system (10′a; 10′b; l′c; 10′d; 10′e; 10 f) is directly surrounded by a conductor traversed by a cooling medium.
 18. The apparatus according to ene claim 11, characterized in that the coil system (10′a; 10′b; 10′c; 10′d; 10′e; lf) has conductors which are insulated by temperature-resistant oxides.
 19. The apparatus according to on claim 11, characterized in that above the coil system (10 f) a field shield (27) preferably of sheet metal or ferrite is arranged.
 20. An apparatus for carrying out the method according to claim 1, characterized in that above the melt bath (4) at least one rotatably journaled magnet carrier (30 h; 30 i) is arranged along each respective casting roll (1, 2) and has a number of cooled permanent magnets (31 h; 31 i) affixed thereto.
 21. The apparatus according to claim 20, characterized in that the magnet carrier (30 h; 30 i) is provided with at least one passage (33) traversed by a cooling medium.
 22. The apparatus according to claim 20, characterized in that the magnet carrier (30 h; 30 i) provided with the permanent magnet (31 h; 31 i) is located within a ceramic tube (32). 